Electronic module

ABSTRACT

Electronic module with components and contact elements arranged on a circuit support. There is suggested a simple and economical arrangement with a plug-in connection integrated in the housing or at least one housing part of the electronic module, while enabling a tolerance compensation. For this, there is provided an insert part comprising pin openings and being movably supported in a recess of the housing or housing part. Through an over-dimension at the junction point of insert part and housing or housing part, an orienting of the pin openings of the insert part with respect to the contact elements is enabled during the formation of the plug-in connection by joining the insert part with the circuit support. Electronic module as a control device in the motor vehicle field.

[0001] Electronic assemblies or modules are used for variousapplications and purposes in many fields; for example, in the motorvehicle field, electronic modules are provided as control devices (forexample as motor control devices or as door control devices) forprocessing the measurement signals of sensors and the output signals ofactuators as well as for controlling various aggregate or assemblyfunctions or components of the motor vehicle, or are in use as fuse andrelay boxes.

[0002] Electronic modules typically consist of a circuit carrier orsupport (for example a circuit board) and a circuit arrangement that isarranged on this circuit support and that consists of components (forexample mounted by means of solder mounting or adhesive mounting) andcontact elements (for example press-in or insertion contacts protrudingperpendicularly to the circuit support, realized through use of thepress-in or insertion technique). For protection against environmentalinfluences, the circuit arrangement is enclosed by a housing. In orderthat the circuit arrangement contained in the housing can be contacted,at least one plug-in socket is integrated in the housing. Each one ofthe plug-in sockets comprises a certain number of openings—so-called pinopenings. The contact elements arranged on the circuit support arepositioned so that respectively one contact element is lead to theoutside centrally through a corresponding pin opening of a plug-insocket. The contact elements of a plug-in socket can be contacted via aconnection plug fitting to the plug-in socket.

[0003] Due to production tolerances, various thermal expansions, and thehygroscopic characteristics (water take-up or moisture take-up) of thehousing and of the circuit support, the (exact) positioning of thecontact elements relative to the pin openings of the plug-in sockets isproblematic, especially in connection with large housing dimensions anda plurality of plug-in sockets integrated in the housing. Moreover, withthe use of press-in contacts as contact elements, there are especiallyhigh demands on the central positioning of the individual contactelements with respect to the pin openings of the corresponding plug-insocket.

[0004] It is the underlying object of the invention to specify anelectronic assembly or module that especially comprises a simpleconstruction and low costs, a high reliability and a simplifiedproduction, as well as advantageous characteristics with respect to thepositioning of the contact elements to the pin openings of the plug-insockets and the loading upon the contacting with the external connectionplug.

[0005] This object is achieved according to the invention by thefeatures of the patent claim 1. Advantageous embodiments of theelectronic module are the subject matter of the further patent claims.

[0006] In the presented electronic module, at least one plug-in socketis decoupled from the housing of the electronic module (supportedfloatingly or movably in the housing of the electronic module), so thatthe pin openings of the plug-in sockets can be oriented according to thecircuit support or according to the contact elements arranged on thecircuit support, so that thereby the pin openings are exactlypositionable. Moreover, several plug-in sockets can be collected orassembled together to form a plug-in socket group, and, in theirentirety, may be decoupled from the housing of the electronic module(supported floatingly or movably in the housing of the electronicmodule). The number of the plug-in sockets of a plug-in socket group isfreely selectable. Suitably, neighboring plug-in sockets are groupedtogether to form a plug-in socket group, in order to keep the absolutedimensions of the resulting plug-in socket group small.

[0007] The housing enclosing the circuit arrangement may, for example,be assembled from several housing parts, for example from the twohousing parts: housing upper part or cover and housing lower part orbase. In this context, the plug-in socket or the plug-in socket groupcan be decoupled from the associated housing part of the electronicmodule (supported floatingly or movably in the associated housing partof the electronic module).

[0008] Due to the decoupling, tolerance problems only play a role withinone plug-in socket or one plug-in socket group, that is to say onlywithin the dimensions of the plug-in socket or plug-in socket groupdecoupled from the housing (these are significantly smaller than thedimensions of the housing or the housing part of the electronic module).

[0009] The plug-in socket or the plug-in socket group is embodied as aseparate insert part for decoupling the plug-in socket or the plug-insocket group from the housing or the associated housing part of theelectronic module. A recess corresponding to the insert part is locatedin the housing and especially in the associated housing part, so thatthe insert part and the housing or the associated housing part can bejoined with one another. The connection or joint of insert part andhousing or housing part is achieved by a form-fit or form-locking shapeof securing elements provided on the perimeter rim of the insert partwith connecting elements that are provided on the inner side of thehousing or housing part and that surround the recess. After the joiningof insert part and housing or housing part, the insert part is movablysupported to be movable in a plane (i.e. in two directions) in therecess of the housing or housing part, and is supported nearly withoutplay by the form-locking connection in a direction perpendicular to thisplane. Upon joining of insert part and housing or housing part, therecess provided in the housing or housing part is closed in a dust-tightsealed manner, by the cooperative interaction of a protruding lip(embodied in the manner of a collar) provided on the perimeter rim ofthe recess, with a groove fabricated on the perimeter rim of the insertpart. In that the width of the groove of the insert part is embodiedlarger than the width of the protruding lip (of the collar) of thehousing or housing part, the movability of the insert part in the planeis ensured on the one hand, and is simultaneously limited on the otherhand. The orienting of the insert part and therewith of the pin openingsof the plug-in sockets or of the plug-in socket group with respect tothe contact elements on the circuit support is achieved during theassembly of the circuit support with the sub-assembly of housing orhousing part and insert part. Thereby, centering pins located on theinsert part engage in receiver bores or holes of the circuit support andorient the insert part locally to the contact elements.

[0010] The number of the connecting elements of the housing or housingpart, and therewith the number of the corresponding securing elements ofthe insert part, is selected depending on the size of the insert part(of the recess in the housing or housing part) and therewith the size ofthe plug-in socket or plug-in socket group, as well as dependent on theforces that are transmitted during the connecting or joining of insertpart and housing or housing part or during the joining of the externalconnector plugs onto the plug-in connections or plug-in sockets.

[0011] The insert part can be produced together with the housing or theassociated housing part in a common production step. Especially, inconnection with a housing that consists of plastic and that is assembledfrom at least two housing parts, the insert part can be producedtogether with the associated housing part in one injection moldingprocess through the use of one (common) family tool, so that an exactpre-assembly of housing part and insert part is possible, and therebylogistically only the pre-assembled part must be handled for the finalproduction (assembly of the circuit support with the complete housing).

[0012] The presented electronic module incorporates and unifies severaladvantages:

[0013] A standardization (modular building block system) can be achieveddue to the modular construction. Through the integration of the plug-insockets and especially through integration of the plug-in socket groupformed by grouping together several plug-in sockets into one insert parthaving smaller dimensions in comparison to the housing dimensions, thefixed functional dimensions for maintaining the tolerances set forth inthe application specifications become smaller, whereby, in connectionwith plastic housings, the repetition or reproduction accuracy ofinjection molding processes can be used in the production of the insertpart, in that the receiving bores or holes in the circuit support areadapted to the measured tool-contacting parts. Through an undercut-freerealization of the decoupling of the plug-in sockets or plug-in socketgroup in the housing part and in the insert part, no (cost entailing)movable sliders are needed in the injection molding tool in connectionwith plastic housings produced by means of injection molding processes.Thereby the production costs of the injection molding tool are lower,short cycle times and long tool service lives arise during theproduction, and therewith also low part prices, and no contamination ofthe injection molded parts (housing part, insert part) occurs fromlubricants that are necessary in connection with movable sliders(economical and ecological advantage).

[0014] The assembly of the insert part with the housing or housing partafter the injection molding process is automatable in a simple manner,whereby a positioning of the insert part is enabled by use of lead-inguides provided in the housing or housing part. Due to the secure andstable securing of the insert part in the housing or housing part, anddue to the sealing against external influences (especially with respectto permeating dust), no additional securing elements or sealing elementsare required, despite the described decoupling. A rattling of the insertpart in the housing or housing part is prevented due to thepre-tensioning between the securing elements of the insert part and theassociated connecting element of the housing or housing part after theassembly of the insert part with the housing or housing part.

[0015] The electronic module will be explained in connection with anexample embodiment with reference to the drawing (FIGS. 1 to 4).

[0016]FIG. 1 shows a three-dimensional view with a cut-away portion ofthe electronic module,

[0017]FIG. 2 shows a three-dimensional view with a cut-away portion ofthe electronic module in various production steps,

[0018]FIG. 3 shows a side view with a cut-away portion of the electronicmodule before the connection of the individual parts,

[0019]FIG. 4 shows a side view with a cut-away portion of the electronicmodule after the connection of the individual parts.

[0020] The circuit arrangement of the electronic module comprisingcomponents 14 is enclosed by a plastic housing 10, assembled from, forexample, two housing parts 1, whereby respectively one cut-away portionof one of the two housing parts 1 is shown in the figures. Forelectrically contacting the components 14 of the circuit arrangementprovided on the circuit support 3, for example embodied as a circuitboard, several press-in or insertion pins as contact elements 15, forexample four groups with respectively 16 press-in pins 15 which arerespectively arranged in a double row, are arranged perpendicularly tothe circuit board 3. These press-in pins 15 are to be inserted intoplug-in sockets 19 for forming a plug-in connection 21 integrated in oneof the housing parts 1, to which plug-in connection 21 correspondingconnection plugs can be externally connected. The recess 17 forreceiving the insert part 2 is provided in the housing part 1 and issurrounded by several release openings 7. At least one plug-in socket 19comprising pin openings 20 for receiving the press-in pins 15 isprovided in the insert part 2. For example, for forming the plug-inconnection 21 it is necessary to provide a connection of the four groupsof respectively 16 press-in pins 15 that are respectively arranged in adouble row, with the plug-in socket group integrated in the insert part2 with four plug-in sockets 19 with respectively 16 pin openings 20 thatare respectively arranged in a double row.

[0021] In the area of the plug-in connection 21 to be formed, thehousing part 1 possesses, on its inner side, a protruding lip 4 that isembodied as a collar and that extends around the recess 17, several (forexample four) rigid non-springy catch hooks 5 with strengthening ribs 6as well as release openings 7 for realizing the undercut-free embodimentof the catch hooks 5 in the injection molding tool (whereby movablesliders can be avoided in the upper part of the injection molding tool).The insert part 2 possesses: a plug-in socket group with, for example,four plug-in sockets 19 (for example with a total of 64 pin openings 20,which are allocated to the four plug sockets 19 of the plug socketgroup); a groove 8 which extends around the outside or perimeter rim,and which corresponds with the collar 4 arranged on the inner surface ofthe housing part, and by means of which a labyrinth seal againstpermeating dust is formed due to the nesting engagement of the collar 4in the groove 8 and simultaneously a support of the insert part 2against tensile loading during the contacting of the plug-in sockets 19is realized; several securing elements 22 (for example four securingelement 22), which correspond with the catch hooks 5 of the housing part1, for supporting or bracing the connected assembly of insert part 2 andhousing part 1 against compressive loading during the contacting of theplug-in sockets 19 or plug-in connections 21 in a directionperpendicular to the tolerance compensating plane, for avoiding forceinfluences on the circuit board 3; as well as (for example two)centering pins 13 (chamfers or bevels) as centering aids for theconnection of the insert part 2 with the circuit board 3 in theformation of the plug-in connection 21. For ensuring a tolerancecompensation in the formation of the plug-in connection 21, groove 8 andcorresponding collar 4 are embodied with a play-fit (that is to say thegroove 8 is provided with an over-dimension). According to theillustrated example embodiment, the securing elements 22 are formed bythe form-locking engagement of a snap element 9 (snap hook) with aprotrusion or protruding shoulder 11 during the joining of the insertpart 2 with the housing part 1, whereby the take-up of high compressiveforce loads is ensured. The form-locking connection based on theprinciple of the shortening of the bending lengths is improved with theuse of a protruding shoulder 11. In connection with small forces, atake-up of the compressive force load can also be achieved solely by thesnap elements 9 (snap hooks), so that the securing elements 22 can beembodied without protruding shoulder 11. Alternatively to this, thesecuring elements 22 can be fixedly connected on the insert part 2 attwo points in the manner of a bail; these securing elements 22 can beembodied rigidly or elastically in the direction of the requiredtolerance compensation, whereby, with a rigid embodiment of the securingelements 22, the corresponding catch hooks 5 of the housing part 1 areembodied elastically. Moreover, the securing elements 22 may compriseintegrated seals 10 and lead-in guides 12 for the positioning of theinsert part 2 with respect to the catch hooks 5.

[0022] On the circuit board 3 there are provided, for example 64press-in pins 15 for contacting the components 14 (for exampleresistors, transistors, capacitors, etc.), as well as for example tworeceiver bores or holes 16 corresponding to the two centering pins 13 ofthe insert part 2 for the (self-finding) orientation of the insert part2 with respect to the circuit board 3 in the formation of the plug-inconnection 21. The pin openings 20 of the plug-in sockets 19 compriselead-in slopes or bevels 23 (see, in this regard, FIG. 3 and FIG. 4) forguiding in the press-in pins 15 in the formation of the plug-inconnection 21.

[0023] The following method steps are provided for the formation of theplug-in connection 21 (in this regard see especially the FIG. 2): Theinsert part 2 with the plug-in socket group including four plug-insockets 19 (FIG. 2a) is moved vertically in the direction of the recess17 of the housing part 1 for insertion into the housing part 1 (FIG.2b). Thereby, the catch hooks 5 on the inner side of the housing part 1at an early time engage into the lead-in guides 12 of the securingelements 22 provided on the outer side of the insert part 2 and therebyfacilitate the self-finding connection or joining of insert part 2 andhousing part 1. Simultaneously, the snap elements 9 of the insert part 2are pressed under the protruding shoulders 11 of the insert part 2 bythe catch hooks 5, and thereby the securing elements 22 are formed (FIG.2c). The assembly motion is ended by the seating of the groove 8extending around the insert part 2 onto the collar 4 that is provided onthe inner side of the housing part 1 and that surrounds the recess 17.At this time point, the snap elements 9 have also passed the undercut ofthe catch hooks 5, and spring back so far until this resetting orrecovering movement is limited by the catch hooks 5. Thereby, the snapelements 9 remain under residual tension; hereby a non-rattlingconnection or joining of the insert part 2 with the housing part 1 isensured (FIG. 2d). After the joining of housing part 1 and insert part2, a labyrinth seal 18 is formed by the cooperative interaction of thegroove 8 extending around on the insert part 2 and the collar 4 providedon the inner side of the housing part 1 (see the sectional illustrationof the FIG. 4). Preferably the groove 8 is embodied wider than thecollar 4, SO that a sliding displacement of the insert part 2 withrespect to the recess 17 in the housing part 1, and therewith apositioning of the insert part 2 or a tolerance compensation in theplane of the housing floor of the housing part 1, into which the insertpart 2 is inserted, is made possible. If the collar 4 is arrangedcentrally relative to the groove 8, a sliding displacement of the insertpart 2 with respect to the housing floor of the housing part 1 andtherewith a tolerance compensation over a distance corresponding to halfof the difference between the width of the groove 8 and the width of thecollar 4 can be achieved. If, for the tolerance compensation, the insertpart 2 is moved perpendicularly to the longitudinal direction of thesecuring elements 22, individual snap elements 9 are de-tensioned (i.e.relaxed) or further pre-tensioned; with a movement in the longitudinaldirection of the securing elements 22, the friction between the snapelements 9 and the catch hooks 5 must be overcome. Hereby, a rattle-freepositioning of the insert part 2 and therewith of the plug-in sockets 19of the plug-in socket group or of the pin openings 20 of the plug-insockets 19 with respect to the press-in pins 15 is realizable. Therelease openings 7 provided in the housing part 1 for avoiding undercutsand the complicated and costly sliders that are necessitated by suchundercuts in the injection molding tool, are closed by parts of thesecuring elements 22 through the joining of housing part 1 and insertpart 2, especially by the snap elements 9 which are tuned or tailored tothe release openings 7 in their geometry (width, thickness, height).After the assembly of housing part 1 and insert part 2, the insert part2 integrated in the housing part 1 is connected with the circuit board 3or with the press-in pins 15 of the circuit board 3, and hereby theplug-in connection 21 is formed (FIG. 2e to FIG. 2g). For this, thepress-in pins 15 are pushed centrally through the pin openings 20 of theplug-in sockets 19 with the aid of the lead-in slopes or bevels 23provided in the pin openings 20 (in this regard see FIG. 3 and FIG. 4).Once circuit board 3 and insert part 2 have sufficiently approached oneanother (FIG. 2f), the centering pins 13 of the insert part 2 begin toplunge into the receiving bores or holes 16 of the circuit board 3,whereby the insert part 2 is finally oriented with respect to thecircuit board 3 in connection with a relative movement in the housingpart 1 that makes a tolerance compensation possible. Thereby, thepress-in pins 15 are exactly positioned to the corresponding pinopenings 20 of the plug-in sockets 19 of the plug-in socket group (FIG.2g). A corresponding external connection plug is connected to theplug-in connection 21 integrated in the housing part 1. Due to theform-locking connection between snap element 9 and protruding shoulder11 (protruding formation of the securing element 22), and the stiffnessin the vertical direction (perpendicular to the plane of the housingpart 1) that is necessitated hereby, a tension or compression forcerelief is realized, depending in which direction the form-lockingconnection is effective, whereby the contact forces that arise in thisregard are transmitted through the insert part 2 without great bendinglengths onto the housing part 1, and do not load the circuit board 3lying thereunder.

[0024] As a result of the above, an electronic module can be realized,with the following features.

[0025] The plug-in sockets integrated in the housing or in at least ahousing part can be grouped and combined together in a simple manner toindividual plug-in socket groups.

[0026] A decoupling of these plug-in sockets relative to the contactelements on the circuit support can be realized without undercuts in thetools provided for the production of the housing or housing part.

[0027] A play-free connection or joining of insert part and housing orhousing part is made possible with the use of an assembly aid, in whicha rattling of the insert part is avoided by pre-tensioning of the snapelements of the insert part, and in which the release openings providedin the housing part (for avoiding undercuts) are covered and sealed byparts of the insert part.

[0028] With centering pins additionally provided on the insert part, apositioning of the insert part integrated in the housing or housing parton the circuit support for forming the plug-in connection is madepossible.

1. Electronic module with contact elements (15) arranged on a circuitsupport (3), with a housing (10) enclosing the circuit support (3) andwith at least one plug-in connection (21) integrated in the housing(10), characterized in that, an insert part (2) comprising pin openings(20) is movably supported in a recess (17) of the housing (10), and inthat the pin openings (20) are orientable with respect to the contactelements (15) during the joining of the insert part (2) with the circuitsupport (3) for forming the plug-in connection (21), through anover-dimensioning at the junction location of insert part (2) andhousing (1).
 2. Electronic module according to claim 1, characterized inthat the insert part (2) comprises at least one plug-in socket (19), inwhich several pin openings (20) are grouped together, and in that the atleast one plug-in socket (19) is oriented with respect to the contactelements (15) during the joining of the insert part (2) with the circuitsupport (3) for forming the plug-in connection (21).
 3. Electronicmodule according to claim 1 or 2, characterized in that the insert part(2) comprises a plug-in socket group with at least two plug-in sockets(19), and in that the plug-in socket group is oriented with respect tothe contact elements (15) during the joining of the insert part (2) withthe circuit support (3) for forming the plug-in connection (21). 4.Electronic module according to one of the claims 1 to 3, characterizedin that the insert part (2) comprises on its rim a groove (8) extendingtherearound, in that the housing (10) comprises a protruding lip (4)surrounding the recess (17), and in that the protruding lip (4) engagesin the groove (8) for the dust-tight sealing of the housing (10) duringthe joining of insert part (2) and housing (10).
 5. Electronic moduleaccording to claim 4, characterized in that the width of the groove (8)is selected larger than the width of the protruding lip (4), so that thepin openings (20) of the insert part (2) are slidably displaceable withrespect to the contact elements (15) during the joining of the insertpart (2) with the circuit support (3) for forming the plug-in connection(21).
 6. Electronic module according to one of the claims 1 to 5,characterized in that the housing (10) on its inner side comprises catchhooks (5) on the perimeter rim of the recess (17), in that the insertpart (2) on its outer side comprises securing elements (22)corresponding to the catch hooks (5), and in that the securing elements(22) engage in the corresponding catch hooks (5) during the joining ofinsert part (2) and housing (10).
 7. Electronic module according toclaim 6, characterized in that the securing elements (22) of the insertpart (2) comprise a snap element (9), a protruding shoulder (11) as wellas a lead-in guide (12) for positioning the securing elements (22) ofthe insert part (2) with respect to the catch hooks (5) of the housing(10).
 8. Electronic module according to claim 7, characterized in thatthe insert part (2), during the joining with the circuit support (3) forforming the plug-in connection (21), is movable in the plane of thehousing (10) through the snap elements (9).
 9. Electronic moduleaccording to claim 7 or 8, characterized in that a stiffnessperpendicular to the plane of the housing (10) is realized by aform-locking connection between snap element (9) and protruding shoulder(11) of the securing elements (22) during the joining of insert part (2)and housing (10).
 10. Electronic module according to one of the claims 1to 9, characterized in that the housing (10) comprises release openings(7) surrounding the recesses (17).
 11. Electronic module according toone of the claims 6 to 10, characterized in that the securing elements(22) of the insert part (2) close the release openings (7) during thejoining of insert part (2) and housing (10).
 12. Electronic moduleaccording to one of the claims 1 to 11, characterized in that thecontact elements (15) are embodied as press-in contacts, which areguided into lead-in bevels (23) of the pin openings (20) during thejoining of the insert part (2) with the circuit support (3) for formingthe plug-in connection (21).
 13. Electronic module according to one ofthe claims 1 to 12, characterized in that the housing (10) is assembledof at least two housing parts (1), and in that a plug-in connection (21)is integrated in at least one housing part (1).
 14. Electronic moduleaccording to one of the claims 1 to 13, characterized in that thehousing (10) consists of plastic and is produced as an injection moldedpart.